Page 1
®
Document 482599
Vari-Green® Transmitter
®
used on AMD-TD Series
Installation, Operation and Maintenance Manual
Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with these instructions will result in voiding of the product warranty and may result in personal injury
and/or property damage.
Transmitter
Version 1.0X
Thermal Airflow & Temperature Measurement System
Regarding This Manual
• This manual should be passed on to the end user.
• Before use, read this manual thoroughly to
comprehend its contents.
• The contents of this manual may be changed
without prior notice.
• All rights reserved. No part of this manual may be
reproduced in any form without Greenheck’s written
permission.
• Greenheck makes no warranty of any kind with
regard to this material, including, but not limited to,
implied warranties of merchantability and suitability for
a particular purpose.
• All reasonable effort has been made to ensure the
accuracy of the contents of this manual. However, if
any errors are found, please inform Greenheck.
• Greenheck assumes no responsibilities for this
product except as stated in the warranty. If the
customer or any third party is harmed by the use of
this product, Greenheck assumes no responsibility for
any such harm owing to any defects in the product
which were not predictable, or for any indirect
damages.
1.0 General Information
1.1 Typical Meter Installation .......................... 2
2.0 Specifications
2.1 Probe Assembly .......................................3
2.2 Vari-Green® Transmitter ...........................3
3.0 Installation
3.1 Inspection ................................................4
3.2 Installation Location Guidelines ..............4
3.3 Transmitter Placement and Mounting .....4
3.4 Power and Signal Connections ...............4
4.0 Configuration
4.1 Configuration ...........................................5
4.2 Start Up/Operation ..................................9
4.3 Analog Output Signals ...........................10
5.0 Maintenance/Inspections
5.1 Maintenance/Inspections .......................10
5.2 Troubleshooting .....................................10
Table of Contents
Safety Precautions
The following general safety precautions must be
observed during all phases of installation, operation,
service, and repair of this product. Failure to comply
with these precautions or with specific WARNINGS
given elsewhere in this manual violates safety
standards of design, manufacture, and intended use
of the product. Greenheck Fan Corporation assumes
not liability for the customer’s failure to comply with
these requirements. If this product is used in a manner
not specified in this manual, the protection providied
by this product may be impaired.
Purpose of This Manual
This manual provides information regarding the
installation, operation and maintenance of your
thermal airflow measurement system. This is NOT,
nor is it intended to be an electrical or HVAC trade
manual.
This manual is the basic reference tool for the
Vari-Green® Transmitter, including its mains power
connection and associated outputs. The complete
system consists of the transmitter and associated
probe array or stations. Refer to supplemental
documents for additional information.
Vari-Green® Transmitter 1
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SECTION 1.0: General Information
®
1.1 TYPICAL THERMAL AIRFLOW MEASUREMENT SYSTEM INSTALLATION
Greenheck’s Vari-Green® system accurately measures the average velocity of flowing air by means of thermal
dispersion at the sensor locations in the duct. Temperature is also measured via these sensors. The Vari-Green
transmitter can receive up to 32 individual flow sensors measuring airflow in a single duct, and it generates the
outputs, including network and analog signals, which are conveyed to a local controller or BMS.
Physical installation details for the probe array or flow stations can be found in Greenheck’s Installation Instructions.
Typical Vari-Green Installation
Thermal Airflow Transmitter
®
Vari-Green® Transmitter2
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SECTION 2.0: Specifications
®
2.1 PROBE ASSEMBLY
INDIVIDUAL SENSOR ACCURACY
Velocity: ±2% of reading from 0-5000 FPM
Temperature: ±0.1° F
Multi-point NIST traceable calibration of both
temperature and velocity
SENSOR TYPE
Her metically sealed, precision matched thermistors with
laser trimmed resistive heating element mounted in
flow conditioning aperture.
Max number of sensors per probe: 8
Max number of sensors per transmitter: 32
SENSOR SIGNAL PROCESSING
Sen sor signal processing at the probe with RS-485
communication to the transmitter
MOUNTING
Ins ertion probe mounting via 4 in. x 4 in. aluminum
plate, 1⁄4 in. closed cell neoprene gasket and end
support stud for probes longer than 18 in.
MATERIALS OF CONSTRUCTION
1.1 25 in. diameter anodized aluminum probe with
aluminum probe connection box
ELECTRICAL CONNECTIONS
Pro be-to-probe connection via plenum rated cable
with mini-DIN Snap & Lock connector for signal and
power
Pro be-to-transmitter connection via a single plenum
rated cable with mini-DIN Snap & Lock connector
Cab le Length: 10 ft. typical, up to 100 ft. optional
(cables can be field terminated to length)
PROBE SIZE RANGE
8 in. to 120 in. dimension length
2.2 VARI-GREEN® TRANSMITTER SERIES
SENSOR DENSITY
Maximum number of sensors per transmitter is
32 total sensors per probe array or measurement station
DISPLAY
Backlit ¼ VGA Color TFT LCD display, 2.75” X 2.0”
Configuration Access:
Field programmable menu driven user interface
accessed via four button membrane keypad. Field
selectable in U.S. or S.I. units for flow, velocity and
temperature.
POWER SUPPLY
24 VAC (20-28 VAC) or 24 VDC (20-40 VDC), isolated
and fused with reverse polarity protection
16-50 VA, varies based on the quantity of sensors
(1-32) in the probe array or station
OUTPUT SIGNALS PROVIDED
Dual analog outputs, field selectable via menu for 0-5
VDC, 0-10 VDC, or 4-20 mADC
Field adjustable analog output scaling of airflow velocity
and temperature
Velocity Range:
0 to 5,000 FPM in Ducted Applications
Temperature Range: -20° to 140° F
AMBIENT CONDITIONS
Temperature Limits: –20° F to 180° F Storage, -20° to
+140° F Operating
Humidity: 0 to 99.9% RH, non-condensing
ENCLOSURE
NEMA 1 aluminum with hinged cover
APPROVALS
UL 60730 PENDING
BTL
FCC Part 15 Subpart B, Class A Device
Vari-Green® Transmitter 3
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SECTION 3.0: Installation
®
3.1 INSPECTION
Carefully remove the Vari-Green probe(s) or station and transmitter from the shipping container and inspect for any
damage.
IMPORTANT: All Vari-Green transmitters are factory configured with the application specific duct size
and flow rate information. The transmitter and probes or flow station are tagged with matching ESID and/
or customer specific identification. Matching the systems as configured by the factory will reduce the
installation and start-up labor required.
Review the Factory Set-Up Information Sheet provided separately and verify that the W.O. # and serial # match
those on the Vari-Green system. Verify that the configuration recorded on the Factory Set-Up Information Sheet is
correct for your application. If any damage has occurred in transit or the factory set-up configuration is incorrect for
your application, please contact Greenheck at 1-800-717-6540.
3.2 INSTALLATION LOCATION GUIDELINES
The standard version of the Vari-Green transmitter and probe connection heads have a NEMA 1 enclosure rating
suitable for clean and dry indoor locations. For additional protection, an enclosure with an adequate NEMA rating
may be required.
The ambient temperature of the selected mounting location must be between -20°F and 140°F. Consideration should
be given to units exposed to direct sunlight.
The selected mounting location should be rigid and free of vibration.
3.3 TRANSMITTER PLACEMENT AND MOUNTING
For placement of transmitter, see instruction manual at www.greenheck.com, 478799 AMD-XX-TD IOM.
3.4 POWER and SIGNAL CONNECTIONS
NOTE: The Vari-Green transmitter terminal connections for power and signal wire are labeled on the board for
installation convenience. Power wiring is located at terminal strip J4. Signal wiring is located at terminal strip J1.
The REMOVABLE* terminal strips for power and signal are located in the lower portion of the transmitter and are
accessible by opening the hinged cover. (See figure below for the exact location of the terminal strips.) Two conduit
openings are provided in the bottom of the transmitter enclosure; one for power and one for signal wiring.
Recommended wire gauge (14 AWG is the maximum wire gauge - no more than two wires recommended per
terminal):
Power wire = 14 AWG to 18 AWG
Signal wire = 14 AWG to 22 AWG
* To aid in the wiring of both power and signal wires, J1 and J4 are removable by pulling the terminal strip straight
up and off the circuit board. Once wiring has been completed, replace the terminal strip by aligning it with the
receptacle and inserting firmly.
WARNING: The Vari-Green transmitter is a low voltage device (24V AC/DC). Connecting the transmitter to
high voltage power (e.g. 110 VAC) may cause damage and will void the warranty.
Power Connections: Terminal J4, pin 1 for Line, pin 2 for Neutral and pin 3 for Ground. See figure below for details.
The Vari-Green can be powered by either 24VAC providing 20-28VAC or 24VDC providing 20-40VDC.
CAUTION: The earth ground is required on all Vari-Green transmitter installations. Omitting the connection to
earth ground could result in poor performance and may void the warranty.
Analog Outputs: Terminal J1; AO1 pins 1 and 2; AO2 pins 3 and 4. Pins 2 and 4 are for the common wire of the
respective output. See figure below for details.
Vari-Green® Transmitter4
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Section 4.0: Configuration
®
4.1 CONFIGURATION
All device configuration is done using the four button membrane keypad on the transmitter cover. Individual key
functions depend on specific menu selection. The basic key functions include:
ENT: Enters menu item from main or service menu; moves cursor to next item when in submenu
ESC: Exits current page or submenu item
UP Arrow: Moves cursor “up” through main and service menu; changes character in submenu items
DOWN Arrow: Moves cursor “down” through main and service menu; changes character in submenu items
MAIN MENU OR SERVICE MENU: ENT opens the highlighted submenu. UP and DOWN move the selection cursor
between submenus.
Submenu: ENT moves selection cursor to the next item. UP and DOWN change state of item or change characters
in writable fields.
MAIN MENU SELECTION DESCRIPTION
Density Compensation Select density compensation type for flow output (Actual or Standard CFM)
Select System of Units Select system of units (US or SI)
Flow Configuration Select and configure flow and application parameters
Display Configuration Select parameters of display screen
Analog Output Configuration Configure analog output type, value and averaging filter
Display Averaging Filter Configure display averaging filter
Zero Lockdown Adjust zero lockdown (below a FPM set point, drives display and output to zero)
Alarm/Alert Configuration Configure alarm type, upper and lower limits
Network Configuration Configure network type, baud rate and address information
Field Characterization For information on field characterization, please see section below
SERVICE MENU SELECTION DESCRIPTION
Password Configuration Enable/disable and change password
Total System Scan Displays sensor enabled/disabled status
Sensor Control Enable or disable system sensors
Sensor Data Scan Displays individual sensor data
Sensor Alert Scan Displays alert codes for each sensor
Custom ID Configure ID (tag) of unit
Restore Factory Setting Restores display settings to original factory setup
Product Information Displays product information (Serial number, Work Order #, etc.)
MAIN MENU
Density Compensation - Density compensation can be selected to be actual flow or corrected to standard
conditions. Default factory setting is for actual conditions. The Vari-Green also allows for inputting the site elevation,
which will add density compensation for average atmospheric pressure based upon elevation above sea level.
Select System of Units - US or SI units can be selected. US units will display in CFM and degrees Fahrenheit. SI
units will display in L/S and degrees Celsius.
NOTE: When changing between US and SI units, the flow configuration information will need to be converted
and updated. This is not done by the transmitter. The user must convert and input.
Vari-Green® Transmitter 5
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Flow Configuration
®
The flow configuration menu provides access to modify the application
specific parameters.
NOTE: All transmitters are factory configured for the intended
application – Changes to the factory configuration should not be
required. A Factory Set-Up Sheet is provided with each transmitter
and provides the details for all factory configured parameters.
The measurement type for all Greenheck Vari-Green applications will be
selected as ducted. One transmitter accepts up to 32 sensors.
Ducted:
Select the proper duct shape
(Rectangular, Flat Oval or Circular).
Enter the duct dimensions (inches or millimeters).
Area (cross-sectional duct area) is automatically calculated.
Enter the Max Flow (maximum airflow) in CFM or L/s.
Display Configuration
This screen allows the user to set parameters on various lines of the
display. There are four display lines on the Vari-Green.
Line 1 - Flow (typical), Velocity or Temperature.
Line 2 - Velocity, Flow or None.
Line 3 - Temperature, Flow or None.
Line 4 - Custom ID or None.
A custom ID can be entered through the Service Menu. It is typically used
to describe the transmitter location in the building.
Brightness - Allows the user to set the brightness of the display in real
time.
Inactivity Timeout - The time period which holds the display in menu
mode. When the timer expires, the display is
returned to the main display screen showing the
process values.
Flow Configuration
Measurement Type:
Shape
Height (In):
Width (In):
Area (ft2):
Max. Flow (CFM):
ENT - Accept ESC - Leave UP/DN - Change
Ducted
Rectangular
6.0
30.0
1.25
2000.0
Display Configuration
Line 1:
Line 2:
Line 3:
Line 4:
Brightness:
Inactivity Timeout:
ENT - Accept ESC - Del/Leave UP/DN - Change
Flow
Velocity
Temperature
ID
100%
60 min
Analog Output Configuration
Analog Output Configuration
The Vari-Green transmitter is equipped with dual analog outputs. The
Analog Output Configuration menu configures the analog output type,
parameter and filter.
Output Type: 4-20 mADC, 0-5 VDC or 0-10 VDC
Output 1 and 2: Flow, Velocity or Temperature
The Filter has a minimum setting of 0 to a maximum setting of 10. To
disable the Filter, select Off.
Display Average Filter
The Display Averaging Filter filters the data shown on the display. It affects
all elements of the display. The Filter has 1-10 settings - 1 is the lightest
filter, and 10 represents the heaviest filter. It also has an ‘Off’ setting.
Output Type:
Output 1:
Output 2:
Filter:
ENT - Accept ESC - Leave UP/DN - Change
4-20 mA
Flow
Temperature
4
Display Averaging Filter
Filter:
ENT - Accept ESC - Del/Leave UP/DN - Change
4
Vari-Green® Transmitter6
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Zero Lockdown
®
Zero Lockdown will drive the displayed flow and velocity, as well as the
associated outputs to zero when the velocity is below the set point. As
very low air velocities tend to be noisy and unstable, it may be best for
control purposes to raise the zero lockdown velocity to an appropriate
threshold above that which the velocity is steady and reliable.
Alarm/Alert Configuration
The Alarm/Alert Configuration menu provides access to select and
configure the transmitter alarm and alerts. Alarm type can be either
flow or temperature with Upper and Lower limits. The transmitter alarm
controls an onboard relay. Alerts are messages possibly indicating
issues with sensors or the transmitter.
Alarm Operation: If the process value (Type) exceeds the Upper or
Lower Limit, the relay will change state from the default of NO or NC
and the Type will change to red. When the process value recovers to
be within the Upper and Lower Limits, the relay will return to the default
state and the Type will return to black. The Limits Units are shown in
parentheses. These units are controlled by the System of Units and the
Units of Measure. If the units are US and the flow is CFH, CFH will be
the units used in Limits.
Alert Operation: Enable Reg. Alerts will turn ON / OFF
Enable Global Alerts will turn ON / OFF
Zero Lockdown
Lockdown
Velocity (FPM):
ENT - Accept ESC - Leave UP/DN - Change
ON
30
Alarm/Alert Configuration
Type:
Upper Limit (CFM):
Lower Limit (CFM):
Enable Reg. Alerts:
Enable Global Alerts:
ENT - Accept ESC - Leave UP/DN - Change
Flow
750
100
OFF
ON
Field Characterization
Field characterization (K-factoring) of a flow element is the adjustment
of the flow measurement system to match a known reference
measurement, (most commonly airflow traverse testing.) Field
characterization is typically done when there is insufficient straight duct
run or another issue that creates questionable output from the installed
measurement system.
A Field Characterization can be developed from one, two or three
reference flow rates – more could be used, but are not necessary. One
traverse test is required for each flow rate. It is recommended that a
minimum of a low and a high flow rate are used to determine a Field
Characterization. If there is little to no variance in the normal flow rate, it
is feasible to use a Field Characterization developed from a single flow
rate test. If a high and low flow rate test are performed and it is found
that these readings are substantially different, then a medium flow rate
should be considered to ensure a more accurate Field Characterization.
For any questions or concerns regarding Field Characterization
implementation, please contact Greenheck.
Field Characterization
On enables the Field Characterization and the selection of Calculate
or Manual. The Calculate selection will display the on-board calculator
that will determine the K-factor (device and reference data must be inhand and ready to input). Manual displays the Exponent and Gain value
forms for inputting externally determined Exponent and Gain values.
Field Characterization
On
Calculate
Manual
ENT - Accept ESC - Leave UP/DN - Change
Vari-Green® Transmitter 7
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Calculate
®
Number of Points is the number of flow reference points. Each point is
one reference flow rate (determined by traverse testing or other) and
the associated Vari-Green system flow rate. The traverse testing flow
rate for these reference points is performed before entering this screen
and is written down with the associated Vari-Green point (flow rate). For
most applications, a minimum of two points (low and high flow rates) are
recommended for an accurate Field Characterization. Three points may
be required.
Electra Point refers to the flow rate measured by the transmitter, and
Reference Point refers to the flow rate measured externally. Electra Point
1 and Reference Point 1 will be the flow rates for the first test, Points
2 for the second test and Points 3 for the third test. Best practice will
be to go from the lowest to highest flow rates when inputting this data.
Once all data has been entered and the ENT button is pushed for the
final Reference Point, the Calculator will display the calculated gain and
exponent values.
NOTE: Whenever a system is being retested in order to determine
a new Field Characterization (K-factor), the existing Field
Characterization should be turned off prior to testing.
Manual
Selecting Manual will allow inputting of externally determined Gain (K)
and Exponent (E) values, where:
Flow (corrected) = K x Flow (uncorrected) ^ E
Note: A Gain (K) only Field Characterization (K-factor) can be
achieved with an exponent (E) value = 1.0.
SERVICE MENU
Total System Scan
Displays the current status of all of the system sensors, thus allowing
the user to quickly verify all is operating properly. Expected (white)
and Enabled (green) sensor values should be the same unless sensors
have been intentionally Disabled (red). See below for sensor control.
If Missing (yellow) is at a value other than zero, the transmitter is not
communicating with the associated node.
Sensor Control
An enabled sensor will report measurement data to the Vari-Green
transmitter. This is the default condition after initially powering the
system. A disabled sensor will not report measurement data to the
Vari-Green transmitter. Disabled sensors may have a malfunction that
causes this condition. It may also be desirable to intentionally disable a
sensor for troubleshooting purposes. A known bad or suspect sensor
can be disabled to remove it from the flow and temperature averages
until it can be evaluated and/or repaired if necessary.
Sensor Data Scan
Displays sensor number (Sen), power input to sensors (PWM),
temperature difference between flow and temperature sensors (DELTAt),
velocity (FPM), flow temperature sensor (FLOWt) and the reference
temperature sensor (REFt).
This data display screen can be used to further evaluate and
troubleshoot the system performance and the application
characteristics; e.g., the individual sensor velocities and temperatures
will provide comprehensive data regarding the flow profile measured.
Characterization Calculator
Number of Points:
Electra Point 1:
1
300.0
Electra Point 2:
Electra Point 3:
Reference Point 1:
400.0
Reference Point 2:
Reference Point 3:
ENT - Accept ESC - Leave UP/DN - Change
Total System Scan
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24
25 26 27 28 29 32 31 32
Expected
Missing
2
ESC - Leave
Enabled
Disabled
2
00
Sensor Control
Sensor 1: Disabled
Sensor 2: Enabled
ENT - Toggle ESC - Leave UP/DN - Select
Sensor Data Scan
Sen PWM DELTAt FPM FLOWt REFt
1 8980 31.3 885.0 104.9 73.6
2 6813 35.0 382.0 108.2 73.2
3 0 0.0 0.0 0.0 0.0
4 0 0.0 0.0 0.0 0.0
5 0 0.0 0.0 0.0 0.0
6 0 0.0 0.0 0.0 0.0
7 0 0.0 0.0 0.0 0.0
8 0 0.0 0.0 0.0 0.0
9 0 0.0 0.0 0.0 0.0
10 0 0.0 0.0 0.0 0.0
ESC - Leave UP/DN - Page Scroll
Vari-Green® Transmitter8
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Sensor Alert Scan
®
Displays alert codes for expected sensors. Sensors operating properly will
display NoAlert.
Sensor Alert Scan
Sensor 1: Disabled
SENSOR ALERT CODE FREQ
1 Disabled 41
2 NoAlLert
Other Alert Codes
ESC - Leave UP/DN - Scroll
Alert Code Type Description Corrective Action
Missing ALERT Transmitter cannot communicate with Sensor Power cycle system and recheck.
SensAOOR
ALERT Sensor fault Replace sensor. Contact Greenheck.
or
SensBOOR
DeltaOOR ALERT Sensor Delta Temperature out of range Contact Greenheck.
TempOOR RANGE Temperature measurement out of range
(-20 to 140°F)
Verify application temperature is not outside -20
to 140°F. If Vari-Green appears to be reporting
incorrectly, contact Greenheck.
Disabled ALERT Sensor resets abnormally Power cycle system and recheck.
VelOOR RANGE Average velocity exceeds 5000 FPM for ducted
and 10,000 FPM for Fan Inlet
Verify factory set-up information is correct. If
application velocity exceeds 5000 FPM, contact
Greenheck.
4.2 START-UP / OPERATION
After power and signal wiring has been verified in accordance with section
3.4, activate the external 24 VAC / 24 VDC power source.
1. Press the power button located on the bottom left corner of the front
cover to turn the system ON.
2. The display will show a loading bar. After reaching 100%, the display
will indicate which sensors have been discovered for approximately 2
seconds. Then the normal operating screen will be displayed.
The default normal operating screen will display Total Flow on the first
process line, Velocity (average of all enabled sensors) on the second
process line and Temperature (average of all enabled sensors) on the third
process line. Application tagging information is at the bottom of the screen
and is customer configurable.
The following icons will always be displayed at the top of the normal operating screen. Press ENT to enter
menu screens. Follow instructions in section 4.1 to navigate.
Total Flow
Velocity
Temperature
520 ACFM
417.1 AFPM
72.71 F
Send/Receive arrows flashing indicates the sensor(s) and transmitter are communicating
normally
Transmitter processor normal
Field Characterization has been turned on
Vari-Green® Transmitter 9
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4.3 ANALOG OUTPUT SIGNALS
Airflow: Available on connector J1, terminals AO1+ and AO1- or AO2+ and AO2-. The full scale output is equal to
Max flow as inputted into the Vari-Green transmitter on the Flow Configuration submenu.
Temperature: Available on connector J1, terminals AO1+ and AO1- or AO2+ and AO2-. The temperature analog
output has a fixed scale of -20º F to 140º F.
SECTION 5.0: Maintenance / Inspections /
Troubleshooting
5.1 MAINTENANCE / INSPECTIONS
The Vari-Green system has been designed to operate in most HVAC applications without the need
for periodic maintenance or calibration. In some applications, it may be necessary to perform a visual
inspection of the probe and sensors, and if necessary clean them using a soft, small brush and/or
compressed air to remove any accumulated particulate or debris.
5.2 TROUBLESHOOTING
The Vari-Green system is intended to provide long-term, trouble-free operation. In the event there is an
issue with the Vari-Green measurement system, or the BMS or the controller ceases to receive valid
airflow and/or temperature signals, make certain the following have been checked and confirmed:
• The power wiring is securely connected to the proper terminals and is providing the intended 24V AC/
DC power.
• The signal wiring is securely connected to the proper terminals.
• The probe-to-probe and probe-to-transmitter cables and connections are properly connected and
secure.
• Power cycles the transmitter.
If after following the above troubleshooting steps, the Vari-Green system continues to operate improperly,
contact Greenheck for technical assistance.
Technical Support:
E-mail: dampers@greenheck.com or
Phone: 1-800-717-6540
Our Commitment
As a result of our commitment to continuous improvement, Greenheck reserves the right to change specifications
without notice.
Product warranties can be found online at Greenheck.com, either on the specific product page or in the literature
section of the website at Greenheck.com/Resources/Library/Literature.
®
Phone: 715.359.6171 • Fax: 715.355.2399 • Parts: 800.355.5354 • E-mail: gfcinfo@greenheck.com • Website: www.greenheck.com
482599 • Vari-Green® Transmitter IOM, Rev. 3, October 2018 Copyright 2018 © Greenheck Fan Corporation10
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